Coil winding method and apparatus



5 Sheets-Sheet 1 H m-HUM R. C. GLAZIER ETAL COIL WINDING METHOD ANDAPPARATUS Feb. 17, 1959 Original Filed Jan. 4, 1954 Q i h: g Q a xv PIEIE.

Feb. 17, 1959 R. c. GLAZIER ET AL COIL WINDING METHOD AND APPARATUSFiled Jan. 4, 1954 Original 5 Sheets-Sheet 2 IE1 lE- 1 3- 1959 R. c.GLAZIER ET AL 2,873,924

COIL WINDING METHOD AND APPARATUS Original Filed Jan. 4, 1954 5Sheets-Sheet 5 Feb. 17, 1959 R. c. GLAZIER ET AL 2,873,924

con WINDING METHOD AND APPARATUS 5 Sheets-Sheet 4 Original Filed Jan. 4,1954 R. c. GLAZIER ET AL 2,873,924

, con. WINDING METHOD AND APPARATUS 5 Sheets-Sheet 5 ma g w 2. \q h 1 am2 m3 IHII I IIHH L- -IH I I 5 -HH 3N fl 41E 1 -H E s: a a O H- l I 8w 5MI L W MH W {lily I \NN 9N g QN o! l I. i W n i hh 5 k 5% l I on 0S a! 1ME M a h l mi 5 2 w SN a Q N a! N! m! 05 P 5 9 m w In IH Feb. 17, 1959Original Filed Jan. 4, 1954 United States PatentO COIL WINDING METHODAND APPARATUS Robert Charles Glazier, Hayward, and Gottfried Zickler,

Castro Valley, Calif assignors to Fridcn, Inc., a corporation ofCalifornia Original application January 4, 1954, Serial No. 401,784.D9igidetll and this application June 18, 1956, Serial No. ,02

7 Claims. (Cl. 242-13) This invention relates to a coil winding method,and apparatus therefor, and more particularly to a coil windingstructure in which a-plurality of coils are applied on a support toprovide a plurality of energizing coils for an electrical apparatus.

The present application is a division of an application in the names ofthe inventors herein indicated,

.Ser No. 401,784, filed January 4, 1954.

energizing coils on a supporting member in which the coils are wound onthe supporting member in a plurality of divided operations, theoperation of winding one coil being accomplished in a plurality ofstages interposed with stages of winding another of the coils.

Another object of the invention is to provide an improved coil windingmachine.

Another object of the invention is to provide an improved wire guidingspindle.

Another object of the invention is to provide an improved wire holdingbobbin.

In the drawings:

Fig. 1 is a view in perspective of a laminated metal core memberforming, in this case, an unwound stator.

Fig. 2 is aview corresponding to Fig. l but showing insulating opensleeves applied to the stator.

Fig. 3 is a view in perspective of a completely wound stator member madein accordance with the invention and is shown in reduced size relativeto the illustrations in Figs. 1 and 2.

Fig. 4 is a view in cross-section of the wound stator shown in Fig. 3.

Fig. 5 shows a first phase winding of insulated wire and the directionsit takes when applied to the stator core.

Fig. 6 shows a second phase winding of insulated wire and the directionsand order of application when applied to the stator core.

Fig. 7 shows a third phase winding of insulated wire and the form anddirection the various turns take when applied to the stator core.

Fig. 8 shows a wiring diagram of the stator made in accordance with thisinvention and in efiect' shows the segments of the stator rolled out ina flat plane.

Fig. 9' is a front elevational view of portions of a winding machinewith a stator member supported therein and partly wound in accordancewith this invention.

Fig. 10 is an end view ofone portion of a two-part chuck member providedin the winding machine.

Fig. 11 is aside view of a wire tensioning and guiding arm memberformingpart of the winding machine.

Fig. 12 shows a stator core member ready to be wound 2,873,924 PatentedFeb. 17, 1859 and a two-part spindle operable to extend through thestator member.

Fig. 13 is a side view partly in cross-section of: a two-part bobbinused in supplying wire to the stator.

In the manufacture of wire wound members such for example as the statorsof gyroscopes, Selsyns and other motor members, and in which a pluralityof phase windings are applied to a core, it is common practice to windeach section of each phase winding from a separate length of Wire and toconnect the various portions of each phase winding by means of solder orother approved wire connecting means and methods. The connections madeby means of solder or other physical means may or may not form goodelectrical connections of the parts and may in some cases introduceelectrical resistance characteristics of an unbalancing andunsatisfactory nature and not tolerable in the structure required.

In the present invention, a plurality of phase windings are applied andinterposed in successive operations while maintaining each phase windingas an unbroken length of wire.

The stator 45 embodying this invention, and as shown in Figs. 3 and 4,comprises a laminated core 14 and a set of windings 46 applied to thecore in a particular manner as will be subsequently described. The core14 is of ferromagnetic material and comprises the layers 15,- 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29 and 30 in the particularillustration used in connection with the explanation of this invention.The number of layers may vary however, as requirements demand. Eachlayer is secured in face to face relation with an adjacent layer orlayers to form the compound structure shown in Figs. 1 and 2. The layersmay be secured together in any suitable manner provided that theystrongly adhere and permit no relative movement between the layers. Inthe particular embodiment of the invention illustrated, it was foundadvantageous to secure the layers together by means of cementitiousmaterial and to use a particular process known as cycleweld. The mannerof securing the layers together, however, is not pertinent to thepresent invention. The laminated core 14, shown in Fig. l, is providedwith spaces 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41 and 42 which arecooperatively defined by the spaced arms 51, 52,53, 54, 55, 56, 57,58,59, 60, 61 and 62, respectively, and which on the outer ends havecross-head portions 71, 72, 73, 74, 7 5, 76, 77, 78, 79, 80, 81 and 82,respectively, the cross-head portions operating to partially close theouter ends of the spaces 31 to 42, inclusive, and in which portions ofenergizing windings are set and seated in various directions ofapplication as will be further brought out in the specification. In Fig.1 the spaces 31 to 42, inclusive, are identified on the layer 15 as therespective positions 1 to 12, inclusive, and are in elfect slots 1 to12, inclusive.

The spaces 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41 and 42 are linedwith insulatingsleeves 91, 92, 93, 94, 95, 96,

97, 98, 99, 100, 101 and 102, respectively, the insulating sleeves beingopen at the outside to permit application therein of the variousportions of the windings as applied. The insulating sleeves may besheets of insulating paper longitudinally folded and slipped into thespaces 31 to 42, inclusive. The outer surfaces of the cross-headportions 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81 and 82 form polefaces 111, 112, 113, 114, 115, 116, 117, 118, 119, 120, 121 and 122,respectively, of magnetic material which are electromagneticallyenergized by the windings 46 when current is applied to the windings.The windings 46 comprise a plurality of windings of wire and form aplurality of phase windings for the stator. Each phase winding is asingle unbroken length of insulated wire and is wound on the stator in aplurality of stages which are interposed with the stages of the otherphase windings. For example, as shown in Fig. 8, there are three phasewindings applied to this stator, .the phase windings being identified asA, B and C, respectively, and one end of each of the windings terminatesin a star connection 125 in which the three windings are electricallyconnected. The other end of each winding forms an outer end of theenergizing system of the stator and comprises the outer ends 131, 132and 133 representing, respectively, the windings A, B and C.

Method of winding It will be seen by looking at Fig. 8 that the firstphase winding A extends from the'outer end through the slot 7 in thestator 14 and proceeds through the slot 11 into the slot 8, from slot 8to 12 and then through slots 6 to 2 to and 1 to the star connection 125.

The second phase winding B can be traced from the outer end 132 throughslots 11, 3, 12, 4 and to C, picking up again at C on the right-hand endof the drawing through slots 6 to 9 to B, picking up again at terminal Bon the right-hand part of the drawing through slot 5 to the starconnection 125.

The third phase winding C may be traced from its outer end 133 throughslots 3, 7, 4, to A, picking up again at A on the left-hand side of thedrawing and proceeding through 8, 2, 10, 1, 9 and to the star connection125. The points A, B and C on the left and right-hand parts of thedrawings are not indications of a break in the phase windings but areillustrated in the manner shown because the drawing is an illustrationof the stator 14 in effect being rolled out ina single plane. It will beunderstood, therefore, that there is no break from the points 131, 132,133 of the three phase windings to the star connection 125 whichrepresents the inner ends of the windings at which point they are allconnected together. The outer ends 131, 132 and 133 are maintained asouter terminals for the attachment thereto of lead-in wires from therequired sources of current supply. In actual practice the windingsshown as single lines in the drawing Fig. 8 are many turns of thewinding wire, and the lines in Fig. 8 are only representative of thedirection taken by the plurality of phase windings provided in thestator.

For example, as shown in Fig. 3, it will be seen that the energizingwindings 46 comprise many strands of wire extending across variousportions of ends of the stator to energize predetermined groups of thepole pieces 111 to 122, inclusive, as required. In an actual stator fromwhich Fig. 3 was drawn each stage of winding comprised 170 turns of wireextending from one predetermined slot to another before the direction ofwinding was changed and after 170 turns of one of'the phase windings hadbeen made from one predetermined slot in the stator to another alikenumber of turns of the next phase winding was made before the firstphase winding operations were com tinued into the second stage. Thispattern of winding is maintained throughout the winding of the statoruntil the required amount of energizing winding applications isobtained. The number of turns applied in winding the stator and thenumber of pole pieces embraced during each stage of the winding willdepend on the particular electrical characteristics desired in thestator. The present invention is not limited to the number of phasewindings applied or the number of turns applied in each operation, butto the method and apparatus and structure in which the phase windingsare applied to the stator core without requiring the'severing andreattachment of Wires in the plurality of phase windings which aremaintained as unbroken lengths of wire from one end of a phase windingto the other end of the phase winding thus requiring no solderconnections or mechanical connections of any kind which might produceundesirable resistance conditions and unbalance efiects in the stator.

In the method of winding a three phase winding stator in accordance withthe present invention, three spools of wire of the required gauge ,andelectrical characteristics are prepared. The wire is fed from the spoolsseparately onto the stator core 14 which is rotated in a suitablewinding machine 156, shown in Fig. 9, and comprising a head stock 151, abase 152 and a. tail stock 153. Supported in and extending from the headstock 151 is a motor driven rotatable shaft 154 which is in registerwith a longitudinally movable shaft 155 extending from and supported inthe tail stock 153, the shaft 155 being movable longitudinally by meansof a lever system 156 pivotally supported at a point 157 on an extensionpiece 158 forming part of the tail stock 153. The manually operatedlever system is mechanically attached to the shaft 155 by means of aclamp structure 159 part of which is clamped at the point 160 to theshaft 155 and the other end is adjustably secured to a screw threadedrod 161 which extends through the clamp 159 and is provided with anadjustment nut 162, the other end being pivotally attached by a boltmeans 163 to the lever system 156. Cooperatively supported on the shafts154 and 155 is a two-part chuck 164, one half portion 165 being securedto shaft 154, the other half portion 166 being secured to the shaft 155.The two parts of the chuck are movable relative to each other byoperation of the lever system 156, to clamp a work piece. between theirwork faces or to release the work piece from the machine 150, the workpiece in the present invention being a stator core 14, shown in Figs. 1,2, 4 and 12, and which has been previously described.

Fig. 10 shows one of the chuck parts to illustrate the work engagingface thereof, both halves of the chuck 164 having the same kind of workengaging faces, a tapered end portion 167 of the chuck half havingformed therein recesses 168 and 169 separated by a projecting rib 170.The recesses 168 and 169 are cooperatively suitable to accommodate thepole faces on the stator core and the rib 170 being operable to extendinto the slots between the pole faces of the stator core. When thestator core 14 is clamped between the parts 165 and 166 of' the two-partchuck 164, as shown in Fig. 9, rotation of the shaft 154 will operate tocause rotation of the stator core 14 which is supported so that the polepieces of the stator core 14 extend transversely of the axis of theshafts 154 and 155. Each phase winding is applied separately to thestator core 14 in operational steps alternated with the operationalsteps in applying the previous winding. That is to say a portion of thefirst phase winding is applied followed by the application of a portionof the second phase winding which is also followed by an application ofa portion of the third phase winding. Another portion of the first phasewinding is then applied followed by a portion of the second phasewinding which is followed by a portion of the third phase winding untilall sections required to be wound are applied. At predetermined pointsin the winding operation the chuck 164 is opened and the stator core 14is rotated to bring into line with the path of feed of the wire otherpredetermined slots of the stator core 14 into which portions of thewindings are to be laid.

Three spools of wire, 171, 172 and 173, are required in winding a threephase winding stator of the type shown and described in this invention.Each spool of wire is used in turn in winding a portion of a phasewinding on the stator core 14, as shown in Fig. 9, which in the par-'spool 172, the wire 182 being supplied therefrom to required portionsof the stator core 14. The wire being instantly applied however, is thewire 183 coming from the spool 173 which is rotatably supported on astem 144 which in this particular position takes the place of the stem174 shown in Fig. 13 and used in the spools 171 and 172 and followingthe structure shown in Fig. 13. The stem 174 supports a sp0ol'175 havingflanges 176 and 177 the major portion of the spool 175 being supportedon the body portion 178 of the stem 174. The body portion 178 islongitudinally bored for a portion of its length to provide a passageway179 to accommodate the shank portion 180 of a screw threaded rod 184which extends into the passageway 179 and has formed on its inner end aconical point 185 eugageable with a ball bearing 186 which upon fullentering of the stem 184 in the passageway 179 is thrust by the conicalend portion 185 outwardly in a lateral opening 187 in the passageway179, the-ball bear-ing 186 being thrust laterally against the innersurface of the barrel portion of the spool 175 to hold the spool 175against rotation on the stem 174. The stem 174 is provided with aknurled flange 188, internally threaded to receive the threaded portionof the rod 184. The male threaded end 191 of the stem 174 is mounted inthe chuck 164.

As shown in Figs. 11 and 9, the stern 144 is supported in an aperturedlever 192 pivotally supported on a screw 193 secured in the lower end194 of a support 195 mounted on a plate 196 secured to the base 152 ofthe machine 150. The plate 196 has pivotally supported thereon a lever198 which extends upwardly from the bolt 199 forming the pivotal supportfor the lever 198, the bolt 199 being entered in and mounted in theplate 196. Lever 198 carries on its upper end a guide pulley 200 anddirectly below the guide pulley 200 there is supported a frictionalcleaner 201 through which the wire 183 passes before going over thepulley 200. The frictional cleaner 201 comprises a pair of plates 202supported on the lever 198, one of the plates 202 being hingedlyattached as at 203 to the lever 198 and the plates 202 having a clip 204provided on the outer end to hold the plates against undue displacementfrom each other. The inner portions of the plates 202 are surfaced withfelt or other suitable friction material, not shown, but operable toserve as a cleaning brush for the wire 183 as it passes on its way fromthe spool 173 and over the pulley 200 to the stator core 14 upon whichthe wire is being wound. As shown in Fig. 11, the lever 192 which ispivotally supported at 193 carries at its outer end a counter weight 205supported on a bolt 206 which is adjustably positioned in an elongatedaperture 307 provided in the lever 192 and the bolt 206 being equippedwith a nut 206' so that the counter weight may be held in any adjustedposition required on the outer end of lever 192. The counterweight 205has the effect of pressing the outer end of the lever 192 downward andto the position shown in Fig. 11. The spool 173 is retained on the stem144 by means of the spring clip 207 which engages inan annular recess,not shown, but provided in the outer end of stem 144.

As shown in Figs. 9 and 11, wire to be wound on the stator core 14 islead from a spool in the position of the spool 173 and under a roller208 supported on a pin 209 mounted in and extending from the lever 192,the roller 208 being maintained against dislodgement from pin 209 byvirtue of a snap washer 210 engaged in an annular recess provided in thepin 209. The pivotally supported arm 198 may be swung to the right or tothe position shown in Fig. 9, as required, so that wire may be wound oneither the left or right-hand side of the stator core 14. In Fig. 9 thewinding is proceeding on the left-hand side of the stator core 14 andthe Wire being fed on to the stator core 14 is coming from the spool173. The spools 171 and 172 are not operated at this time to supply wireto the stator core 14 but are rotated around with the sta- .tor core 14since ends of the wires 181, 182 leading from the spools 171 and 172,respectively, already have portions wound on the stator core 14 and moreportions of wires 181 and 182 have to be subsequently wound on thestator core 14 and it being necessary to maintain the wires 181 and 182in unbroken condition until the full winding operation of the statorcore 14 is completed. The extent of movements of the lever 198 iscontrolled by means of a lever toggle joint system 211, one movablemember 212 of which operates between adjustable stop screws 213 and 214mounted in internally threaded wing portions 215 and 216, respectively,extending from the plate 196.

The half chuck portions and 166 are provided with ring members 217 and218, respectively, which are secured in place on the half chuck portions165 and 166, respectively, by means of set screws 219. The ring members217 and 218 are provided with internally threaded and diametricallydisposed recesses 220 in which threaded end portions 191 of the stems174 in the spool assemblies 171, 172 and 173 may be mounted as requiredwhen the spools are required to be carried around with the chuck 164during portions of the winding operations. The spools 171, 172 or 173may be mounted in either the left-hand portion 165 or the righthandportion 166 of the chuck 164 as required depending on whether or not theinstant winding application is being conducted on the left or the rightside of the stator core 14. In Fig. 9, the spools 171 and 172 are on theright-hand portion of the chuck 164 since the instant point of windingapplication is on the left side of the stator core 14 supported betweenthe chuck portions 165 and 166. It will be obvious that when the windingis being conducted on the right side of the stator core 14 the spools171, 172 or 173 may be mounted in the ring member 217 in the left-handportion 165 of the chuck 164. When the first portion of the first phasewinding is being applied to the stator core 14 no spools of wire arecarried around by the chuck 164, the spool of wire supplying the instantportion of the winding being mounted on the pin 144 extending from thelever 192. When the first portion of a winding has been applied thespool is removed from the pin 144 and is mounted on the chuck 164,another spool of wire may be mounted on the chuck diametrically oppositeto the first spool to counterbalance the weight and mass of the firstspool. As shown in Fig. 9, a spindle 221 is provided to hold ends ofwire coming from the spools carried around by the chuck 164. The spindle221 comprises two parts, as shown in Fig. 12. The lower part 222 has areduced diameter and internally threaded upper portion 223 constructedand arranged to extend through the central opening 103 in the statorcore 14. The internally threaded portion 224 of the portion 223, isdimensioned and threaded to receive the external threaded portion 225 onthe upper part 226 of the two-part spindle 221. The shoulders 227 and228 of the respective lower and upper parts 222 and 226 of the spindle221 are arranged to engage upper and lower faces of the stator core 14when the parts shown in Fig. 12 are brought together with the upper andlower parts 226 and 222, respectively, of the two-part spindle 221 inscrew threaded engagement to their full extent. The lower part 222 has atapered end 229 terminating in an annular groove 230 producing a buttonlike extreme lower end portion 231. The upper part 226 of the spindle221 is tapered at 232 and terminates in a reduced end portion 233 inwhich an annular groove 234 is formed. The annular grooves 230 and 234formed in the respective parts 222 and 226 of the two-part spindle 221provide spaces in which ends of the wire coming from a spool may beanchored at the beginning of the winding operation, these initial endsbeing subsequently secured together in the star connection 125. Alsoportions of the wire may be snubbed in the grooves in the spindle 221when the spool of wire is being carried by the chuck. When winding fromthe present resting spool is to be resumed the wire may be released fromthe end portion of the spindle. After the winding operations arecompleted outer ends of the windings are severed from their respectivespools and are attached to insulated leadout wires, 235, 236 and 237,respectively, which are bound together with a suitable application oftape 238. Portions of the windings are lashed together at suitablepoints by pieces of fish line 239 or other suitable strong lashingmaterial shown in Fig. 3.

To protect portions of the windings located in the grooves of the statorcore 14 from becoming dislodged from their points of rest insulatingstrips 240 are slipped into place between the windings and the innersurfaces of the cross head portions 71 to 82, inclusive, of the polepieces 111 to 122, inclusive.

The order of winding may be changed as required as long as the firstcoil of every phase is wound before the second coil of any phase iswound. Likewise any third coil may be wound as long as all second coilshave been wound. For example, the winding sequence could be M. windingsequence could be 53, A, C; 5C, 5B, 5A; A,

Although the invention has been shown and described as being applicableto the production of a stator involving three windings on a core it isobvious that the number of windings applied may be other than the numbershown herein and the completed structure might be a rotor instead of astator without departing from the spirit of the invention.

We claim:

1. The method of alternately applying wire from a plurality of wiresupplies to a rotating support and repeating the applications without inany case severing the wire supplied, comprising carrying each supply ofwire around with said support except the supply being instantly used toapply wire to the support and subsequently making each supply of wirethe instant source of supply while the other sources of supply arecarried around with the support.

2. The method of forming a plurality of energizing windings on a supportcomprising rotating said support, feeding wire to said support from afirst source of wire supply until a predetermined amount of said wirehas been wound on said support, carrying said first source of wirearound with said support and at the same time feeding wire to saidsupport from a second source of wire supply until a predetermined amountof wire from said second source of supply has been wound on said supportand subsequently winding wire from said first source of wire supply ontosaid support while said second source of wire supply is carried aroundwith said support.

3. The method of forming a plurality of phase windings on a supportcomprising rotating said support, feeding wire to said support from afirst source of wire supply until a predetermined amount of said wirehas been wound on said support, carrying said first'source of wirearound with said support and at the same time feeding wire to saidsupport from a second source of wire supply until a predetermined amountof wire from said second source of supply has been wound on saidsupport, carrying said second source of wire around with said supportand at the same time feeding wire to said sup- Also for example the.

port from a third source of wire supply until a predetermined amount ofwire from said third source of supply has been wound on said support,carrying said third source of supply around with said support and at thesame time supplying wire from said first source of supply to saidsupport. 7

4. The method of forming a plurality of energizing windings of wire on asupport comprising rotating a member, supporting said support in saidrotating member, providing a fixed holder, supporting a first supply ofwire on said holder, feeding wire from said first supply to saidsupport, supporting said first supply of wire on said rotating member,supporting a second supply of wire on said holder, feeding wire fromsaid second supply to said support, supporting said second supply ofwire on said rotating member, supporting a third supply of wire on saidholder, feeding wire from said third supply to said support andrepeating the order of Winding without having to sever any of the wireapplied during the entire winding operation. I

5. The method of forming a three phase energizing winding structure on acore of magnetic material provided with spaced pole portions comprisingrotating said core, supplying wire to said core from a first supplysource at a stationary position relative to said core, carrying saidfirst supply source around with said core, supplying wire to said corefrom a second supply source at a stationary position relative to saidcore, carrying said second supply source around with said core,supplying wire to said core from a third supply source at a stationaryposition relative'to said core and repeating the operation, all withoutsevering the wires leading from the sources to the core.

6. Apparatus for winding wire on a core comprising a rotatable chuckoperable to hold the core, means to rotate said chuck, a relativelyfixed feeding station for said wire, a supply of wire at said feedingstation, supporting means on said chuck operable to support supplies ofwire after portions have been wound on said core and a spindle operablefor mounting in said core and having end portions formed to holdportions of wire extending from supply sources of wire to said corewhile said core and chuck are rotating.

7. Apparatus for winding wire on a core comprising a two-part rotatablechuck, the two parts thereof being cooperable to hold said core inposition for winding Wires thereon, mounting means on each of the twoparts of said chuck for holding spools of wire for winding on said core,a spool of wire supported at a fixed position relative to said chuck andoperable to supply wire to said core and a spindle mounted in said coreand extending therefrom and operable to support portions of the suppliesof wire during the winding operations.

References Cited in the file of this patent UNITED STATES PATENTS598,273 Oehring Feb. 1, 1898 2,035,379 Stewart Mar. 24, 1936 2,042,968Siegenthaler June 2, 1936 2,763,444 Burlein Sept. 18, 1956

